UNIVERSITI TEKNIKAL MALAYSIA MELAKA

MATERIALS SELECTION FOR CONCEPTUAL

AUTOMOTIVE HOOD DESIGN USING FINITE

ELEMENT ANALYSIS

This report submitted in accordance with requirement of the Universiti Teknikal Malaysia

Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Design) (Hons.)

by

MOHD RIDZWANIL HANIF BIN RUSLAN

B051010081

861220-02-5459

FACULTY OF MANUFACTURING ENGINEERING

2013

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

Cop Rasmi:

Tarikh: _______________________

Disahkan oleh:

TAJUK: MATERIALS SELECTION FOR CONCEPTUAL AUTOMOTIVE HOOD DESIGN

USING FINITE ELEMENT ANALYSIS

SESI PENGAJIAN: 2012/13 Semester 2

Saya MOHD RIDZWANIL HANIF BIN RUSLAN

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti

Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan

pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan (√)

(Mengandungi maklumat yang berdarjah keselamatan

atau kepentingan Malaysiasebagaimana yang termaktub

dalam AKTA RAHSIA RASMI 1972)

SULIT

TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan

oleh organisasi/badan di mana penyelidikan dijalankan) TIDAK TERHAD

Alamat Tetap:

A 66,Felda Pasir Besar,

72430 Gemas, Negeri Sembilan.

Tarikh: .

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi

berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai

SULIT atau TERHAD.

DECLARATION

I hereby, declared this report entitled “materials selection for conceptual automotive

hood design using finite element analysis” is the results of my own research except

as cited in references.

Signature : ………………………………………….

Author’s Name : MOHD RIDZWANIL HANIF BIN RUSLAN

Date : 3 JUNE 2013

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of

Universiti Teknikal Malaysia (UTeM) as a partial fulfillment of the

requirements for the degree of Bachelor of Manufacturing Engineering

(Manufacturing Design) (Hons.). The member of the supervisory is as follow:

………………………………

(Project Supervisor)

Engr. Dr. Hambali bin Arep@Ariff

i

ABSTRAK

Sejak kebelakangan ini, gentian asli muncul menjadi bahan sisa yang dapat

menggantikan gentian sintetik yang mahal harganya. Diantara bahan yang digunakan

untuk fabrikasi automotif hud seperti Aluminum Alloy, Magnesium Alloy, Carbon

fiber dan gentian asli adalah Kenaf diperkukuhkan dengan Polipropilena. Projek ini

secara keseluruhannya membincangkan tentang potensi komposit gentian serat

semulajadi terhadap industry automotif dalam rekabentuk hud kereta. Matlamat

utama projek ini adalah untuk menentukan bahan yang sesuai untuk digunakan

dalam fabrikasi hud kereta. Perisian CATIA digunakan untuk merekabentuk semula

hud kereta dan mengunakan perisian SolidWorks Simulationxpress untuk melakukan

analisa. Selepas itu daripada keputusan analisa, perbandingan dibuat dari segi jisim,

tekanan, anjakan dan faktor keselamatan digunakan untuk pemilihan bahan.

Daripada keputusan analisis, data tersebut dimasukan ke dalam scoring process dan

dibincangkan dengan lebih terperinci. Potensi komposit gentian serat semulajadi

akan dikaji berdasarkan keputusan analisis tersebut. Berdasarkan data analisis yang

diperolehi hasil daripada ujikaji yang dijalankan, Magnesium Alloy adalah bahan

yang sesuai untuk menghasilkan hud automotif. Walau bagaimanapun, gentian

Kenaf diperkukuhkan dengan Polipropilena mempunyai potensi untuk mengantikan

bahan sedia ada yang digunakan dalam pembuatan hud kereta. Untuk cadangan

dalam penyelidik akan datang adalah untuk menguji menggunakan analisis dinamik

kemudian, ujian kesan sebenar pada hud automotif direka perlu menjalankan untuk

mendapatkan hasil eksperimen. Hasil eksperimen boleh dibandingkan dengan

analisis yang telah dibuat sebelum ini dan juga boleh menentukan penyerapan tenaga

daripada bahan-bahan yang digunakan.

ii

ABSTRACT

In recent years natural fiber appear to be the outstanding materials which come as

the viable and abundant substitute for the expensive and non-renewable synthetic

fiber. Among the materials used for the fabrication of automotive hood such as

Aluminum Alloy, Magnesium Alloy, Carbon fiber and natural fiber is Kenaf Fiber

reinforced Polypropylene. This project overall is discussed about the potential of

natural fiber composite in automotive industry to develop the automotive hood. The

main objective in this project is to determine the appropriate material to be used in

fabricating automotive hood. From design a hood car by using CATIA CAD

Software and conduct the design analysis using SolidWorks Simulation software.

Redesign the automotive hood is done in the CATIA CAD. SolidWorks

Simulationxpress software was used for Finite Element Analysis. For the

comparison, the mass, stress, displacement and factor of safety is used for materials

selection. From the results, the data were through the scoring process and discussed

in detail based on the result from the Finite Element Analysis. Based on analysis of

data obtained as a result of the test, the Magnesium Alloy is the best material for

fabricated automotive hood. However, Kenaf fiber reinforced with polypropylene

has the potential to replace existing materials used in the manufacture of car hood.

For the recommendation in the future researcher is to test using Dynamic analysis

then, an actual impact testing on the fabricated automotive hood should be conduct

to obtain an experimental result. The experimental result could be compared with the

analysis that has been made before and also can determine energy absorption of the

materials used.

iii

DEDICATION

To my beloved parents, of course;

To my lecturers, my friends and to all members of the

Faculty of Manufacturing Engineering.

iv

ACKNOWLEDGEMENT

The special thank goes to my helpful supervisor, Engr. Dr. Hambali bin Arep@Ariff

the supervision and support that he gave truly help the progression and smoothness

of the project. The co-operation is much indeed appreciated. A big contribution and

hard worked from you during the completion of this project is very great indeed. All

projects during the program would be nothing without the enthusiasm and

imagination from you. Great deals appreciated go to the contribution of my faculty -

Faculty of Manufacturing Engineering (FKP). An appreciation also goes to my

parents for their love and moral support. Last but not least I would like to thank my

friends especially those who work together my PSM group under Engr. Dr. Hambali

bin Arep@Ariff.

v

TABLE OF CONTENTS

Abstrak i

Abstract ii

Dedication iii

Acknoeledgement iv

Table of contents v

List of Tables viii

List of Figures ix

List of Abbreviations x

CHAPTER 1: INTRODUCTION

1.1 Background 1

1.2 Problem Statement 2

1.3 Objective 2

1.4 Scope of project 3

CHAPTER 2: LITERATURE REVIEW

2.1 Introduction 4

2.2 Automotive Hood 5

2.3 Material Used in Manufacturing Automotive Hood

2.3.1 Carbon Fiber Reinforced (CFRP) 8

2.3.1.1 Manufacturing Process of Automotive Hood

Using Vacuum Bagging 9

2.3.2 Aluminum Alloys 11

2.3.2.1 Manufacturing Process of Automotive Hood

Using Blow Forming 12

2.3.3 Magnesium Alloys 13

2.3.3.1 Manufacturing Process of Automotive Hood

Using Sheet Hydroforming with Punch 16

2.4 Comparison of existing material properties and natural fibers. 17

vi

2.5 Natural Fiber 18

2.5.1 Background 19

2.5.2 Kenaf 21

2.5.3 Kenaf Fiber Reinforced Polypropylene 22

2.6 The Importance of Natural Fiber Composite in Product Development 23

2.7 The use of natural fiber in automotive industry 25

2.8 3D CATIA CAD Software 26

2.9 Analysis Software 27

2.9.1 Finite Element Analysis 27

2.9.2 Linear Static Analysis 28

2.10 Pedestrian Impact 29

2.10.1 Requirement for Pedestrian Impact 30

2.11 Materials Selection using Finite Element Analysis 32

2.12 Summary of Literature Review 33

CHAPTER 3: METHODOLOGY

3.1 Introduction 34

3.2 Flow Chart of Methodology 35

3.2.1 Project Planning 36

3.3 Automotive Hood Design Using CATIA 39

3.4 The Analysis Flow Chart of Finite Element Analysis 42

3.4.1 Define the Materials 43

3.4.2 Boundary and Loading Conditions 43

3.4.3 Meshing Process 45

3.5 Material Selection 48

CHAPTER 4: RESULTS & DISCUSSION

4.1 Introduction 49

4.2 Finite Element Analysis using SolidWorks

vii

4.2.1 Analysis of Automotive Hood using Aluminum Alloy 50

4.2.2 Analysis of Automotive Hood using Magnesium Alloy 52

4.2.3 Analysis of Automotive Hood using Carbon Fiber Reinforced 54

4.2.4 Analysis of Automotive Hood using

Kenaf Fiber Reinforced Polypropylene 56

4.3 Summary of SolidWorks Analysis 58

4.3.1 Materials Selection 60

4.4 Discussion Finite Element Analysis 61

4.4.1 Mass 61

4.4.2 Displacement 62

4.4.3 Stress 63

4.4.4 Factor of Safety 64

CHAPTER 5: CONCLUSION & RECOMMENDATIONS

5.1 Conclusion 65

5.2 Recommendations 67

REFERENCE 68

APPENDIX

Appendix A 74

Appendix B 75

Appendix C 77

Appendix D 79

Appendix E 81

viii

LIST OF TABLES

2.1 Existing material properties 17

2.2 Properties of natural fiber and synthetic fibers 17

2.3 Types of natural fiber and general families 19

2.4 Advantages and Disadvantages of Commercial Composite 20

2.6 Mechanical properties for Kenaf Fiber Reinforced Polypropylene 23

2.7 Headform for child’s or an adult’s head. 31

4.1 The Analysis of Automotive Hood made fromAluminum Alloy. 50

4.2 FEA result using SolidWorks with 50N load (Aluminum Alloy) 51

4.3 The Analysis of hood car made from Magnesium Alloy. 52

4.4 FEA result using SolidWorks with 50N load 52

4.5 The Analysis of Automotive Hood made from Carbon Fiber Reinforced. 54

4.6 FEA result using SolidWorks with 50N load 54

4.7 The Analysis of Automotive Hood made from Kenaf Fiber Reinforced

Polypropylene. 56

4.8 FEA result using SolidWorks with 50N load 56

4.9 The Factor of Safety of each materials for Automotive Hood. 58

4.10 The Displacement of each materials for Automotive Hood. 59

4.11 The Stress of each materials for Automotive Hood. 59

4.12 The Results from the Static Analysis 60

4.13 The Scoring Process 60

4.14 The mass based on FEA result using SolidWorks. 62

4.15 The Comparison of displacement result between different materials 62

4.16 Comparison of Stress result between different materials 63

4.17 Comparison of Factor of Safety result between different materials 64

ix

LIST OF FIGURES

2.1 Components of Automotive Hood 5

2.2 Components to be assembled into the hood assembly. 8

2.3 Vacuum bag configuration 11

2.4 Die Structure and Formed-Panel Extraction 13

2.5 SHF-P “short stroke” press 16

2.6 Kenaf Fiber 21

2.7 Computer simulation model of car-pedestrian impact 30

2.8 European Consumer 31

2.9 Head impact for children or an adult’s head 32

3.1 Flow chart of methodology 35

3.2 Starting before start the drawing 40

3.3 Insert the lines, select ‘Styling Sweep’. 40

3.4 Complete design of hood car. 41

3.5 The Process Flow of Finite Element Analysis using SolidWorks. 42

3.6 The boundary condition for Automotive Hood 44

3.7 The Load Force applied to the Automotive Hood. 45

3.8 The type of meshing 46

3.9 (a) Meshing process for the top Automotive Hood. 47

3.9 (b) Meshing process for the bottom Automotive Hood. 47

3.10 Result for Stress, Displacement, Deformation and Factor of Safety 48

x

LIST OF ABBREVIATIONS

CAD - Computer Aided Design

CBU - Completely built-up Units

CFRP - Carbon Fiber Reinforced Plastics

FEA - Finite Element Analysis

FOS - Factor of Safety

FYP - Final Year Project

GFRP - Glass Fiber Reinforced Plastics

kJ - Kilo Joule

LSTC - Livermore Software Technology Corporation

N

PEEK

-

-

Newton

Polyether ether ketone

PSM1 - Projek Sarjana Muda 1

PSM2 - Projek Sarjana Muda 2

RTM - Resin Transfer Mold

SHF-P - Sheet Hydroforming- Process

UK - United Kingdom

3D - Three Dimension

xi

1

CHAPTER 1

INTRODUCTION

Overall this chapter discusses about the briefing of the background, problem statement,

objectives and scope of project.

1.2 Background

Nowadays, in the development of technology, especially in the engineering field among

the engineers create a more creative and competitive in the form or creating new

products. They must be accurate, precise and shows careful attention to what they

produce. The biggest demand facing the automotive industry has provided safer vehicles

with high fuel efficiency at minimum cost. One option for reduce energy consumption is

the weight reduction.

The automotive market is going towards a green approach at the present time, especially

because of marketing purposes. Thus, automotive industries are starting to project and

design cars with less environmental impact. This process is pursued through many

different ways. The most known and advertised is for sure the reduction in the

consumption of fossil fuels. A different way that could be followed in order to reduce

the environmental impact is to decrease the quantity of material used for each a part.

This reduction of materials brings many different improvements. First of all, it has direct

benefits due to a less use of raw materials and energy for parts production. At a second

stage, it has an indirect influence on fuel consumption due to the lower weight of the car

(less weight implies less consumption) (Tolouei, 2009).

2

1.2 Problem Statement too short

The hood car is the hinged cover over the engine of motor vehicles that allows access to

the engine compartment for maintenance and repair. The hood car available in market

now is heavy and finding other alternative to reduce weight on a car component and so

the fuel consumption can be reduced. Kenaf leaf fiber is an alternative material to

explore the new material instead of existing material and to encourage green product.

Automotive hood also one of the related safety features in automobile that need to

consider. The target is designing the automotive hood is to achieve low weight and high

stiffness.

Most of the researcher focus to replacing the conventional materials by develop and

tested the automotive hood with different type of materials, such as conventional

material and composite material. From the material result that shows the lower value of

the stress indicates the better performance of the material and that can propose as new

materials for the automotive hood.

1.3 Objective

The main objective in this project is to determine the appropriate material to be used in

fabricating automotive hood. In order to achieve this main objective, these specific

objectives need to be carried out:

a) To design a hood car by using CATIA CAD Software,

b) To conduct design analysis using SolidWorks Simulation software.

c) Comparison existing material and Kenaf Fiber Reinforced Polypropylene.

3

1.4 Scope of project

The scopes of this project are the utilization of CAD software in designing automotive

hood, find the mechanical properties of materials in FEA using SolidWorks

SimulationXpress, analyzes the compatibility of Kenaf Fiber Reinforced Polypropylene

as material used in fabricating automotive hood based on the result of the analysis.

4

CHAPTER 2

LITERATURE REVIEW

In this section, the focus area is about finding the information of fabricating automotive

hood using natural fiber. The existing materials that are used to fabricate automotive

hood is also be discussed in this chapter.

2.1 Introduction

A typical automotive body is a complex structure comprised of many sub-assemblies

each made of many parts. Often times these parts are sheet metal stampings that must be

joined together using spot weld or hemming processes to make the subassemblies. The

final shape of automotive structures is not only affected by residual stresses in the

individual stamped parts, but often times by the assembly process (Hammett, 1998).

Automotive companies typically use a sequential validation process whereby individual

stampings are compared to their printed specifications during the die buy-off stage. If

the parts do not conform, then the die is reworked until the stamped parts do conform.

Often times this effort is wasted as the part would take its desired shape when joined to a

stiffer part during the subsequent assembly process. Alternatively, the assembly process

itself can distort the shape of individual panels that were produced within specification.

The functional build approach recognizes this fact and attempts to take advantage of it:

5

relatively cheap assembly fixtures are used to ensure that during assembly the out of

spec components are brought within spec (Hammett, 1998).

2.2 Automotive Hood

Today, the automobile industry in Malaysia is getting better and wider day by day.

Many improvements have been done to increase the quality of the automotive products

and at the same time trying to preserve the environment. In the 1960s, the Malaysian

government encouraged the setting up of automobile assembly plants in Malaysia. The

main objectives were to reduce the imports of completely built-up units (CBU) that will

help to stabilize balance of payments, to create employment and to provide the base for

transfer of technology. In the 1970s, the “Local Content Policy” was promoted to

enhance the development of local parts and components industry (Mahidin and

Kanageswary, 2004). A significant effort made by the automobile and component

manufacturers to reduce aerodynamic drag, noise and vibration. Figure 2.1 shows the

components of automotive hood.

Figure 2.1: Components of Automotive Hood (Annoy, 2012)

It can also be considered as another door hood of vehicle. It is the gateway to get access

to the front of the engine compartment of vehicle engine. (Component called for vehicle

rear deck lid engine.) It consists of inner and outer panels. Consists of one-piece frame

6

bracket crisscrossing, internal panel serves as abdominal support panel off so it would

not be easy to flex and get dented. Outer panel, on the other hand, is designed to meet

the sheet metal and fenders and edge contour matches the cowl. It under hood system

shield from rain, road debris, and any other elements that are not supposed to be in the

engine compartment.

Hoods come in designs and styles. There are some who undersides are covered with

sound-absorbing material to minimize the roar or sound escape the engine bay. There are

also specially designed to accommodate their special accessories, such as a spoon. This

is usually found in performance vehicles such as trucks, or sports cars. Very similar to

the airways in form and function, allowing the engine bay spoon to "inhale" and

"exhale." They installed facing the front end of the vehicle can "scoop" or channel

outside air directly to the air filter, which improves engine performance. But there is also

a spoon with their openings facing backwards. Instead of taking the air, they are

designed to release the hot under hood air, which also helps the performance of the

engine.

Usually, the shape and form of the vehicle will carry standard setting design

manufacturer. Hood shaped and contoured to perfection to radiate the presence of the

day, it also serves as a protective cover for the engine to prevent the intrusion of water

and debris. High grade and durable construction effectively shield the rain, snow, hail, or

debris that can reach into the car's engine system and disrupt the smooth operations.

Maintain a good quality engine ensures excellent performance in keeping it away from

damage while only look great on the vehicles front propagation. Hoods are usually

crafted from steel and glass or carbon fiber but aluminum construction is getting more

and more popular for pliability, strength, and handling characteristics of a perfect if you

want to customize the look and shape of the vehicle. It has binders and support that

holds it upright and prevents accidents while having routine maintenance done (Annoy,

2012). Secured with locking feature, it is pressed by the latch pin hidden with scarves.

For the application of high performance parts, should ensure that a proper latch works to

prevent it from opening immediately began to accelerate. For added security features,

7

design hood modified to limit the severity of pedestrian injuries in the accident. More

advanced designs make use of automotive bonnet / hood as actively reject structure a

few centimeters away from the hard parts of the motor by means of the spring force

mechanical or pyrotechnic devices.

The vehicle consists of a large steel section that forms the body of the vehicle. They

were stamped in a particular form and they have been divided to perform different

functions. Frame serves as the overall structure of the vehicle body and good anchor

point suspension system. One that serves as the floor of the vehicle, which is located at

the bottom of the car assembly and also serves as the basis for the vehicle body shell is

the floor pan. These are just some vehicle panels designed to provide a solid amount of

vehicle systems.

Hood is another body panel that has a specific job to do. It's a body in front of the

opening panel cowl that covers the engine in front engine vehicles. In the UK, they are

called the "bonnet". They also considered other types of doors that are fitted in the

vehicle because they are also made up of the outer panel and the inner panel. Inner panel

provides strength while the outer panel only works as a metal cover or function as a

"skin" hood (Annoy, 2012).

Usually, under the hood is covered with sound absorbing material. Many scarves are

manufactured with a built-in spoon although some can only be added. These spoons are

often made of steel, carbon fiber glass. Since the cap is located in the front of the vehicle,

they are prone to wear and tear caused by collisions. But other than collision, corrosion

or rust also archenemy hood because the hood is exposed to many elements that come

from the outside world. The Figure 2.2: shows that, the inner panel (a), the outer panel

(b), and the assembly (f) are cropped to prevent identification, a) Hood inner b) hood

outer c) main reinforcement d) hood hinge reinforcement e) latch reinforcement f)

assembly without the outer panel. Figure 2.2 shows the components to be assembled into

the hood assembly.

8

Figure 2.2: Components to be assembled into the hood assembly. (Thomas, 2010)

2.3 Material Used in Manufacturing Automotive Hood

2.3.1 Carbon Fiber Reinforced (CFRP)

Carbon fiber reinforced composites (CFRPs) offer greater stiffness and strength than any

other type, but they are considerably more expensive than GFRP. Continuous fibers in a

polyester or epoxy matrix give the highest performance. The fibers carry the mechanical

loads, while the matrix material transmits loads to the fibers and provide ductility and

toughness as well as protecting the fibers from damage caused by processing conditions.

Concern about carbon dioxide emissions and world hydrocarbon fuel reserves means

that there is considerable interest in technologies that reduce fuel consumption for

passenger cars. In the area of vehicle design, body weight is the most important target

for improvement, as a reduction in the weight of a vehicle’s body means that a smaller

engine, and a lighter drive train and assembly can be used. This ‘benign spiral’ leads to

further mass reductions, so much so that various studies have indicated a potential for

savings of up to 65% by using carbon fiber composites instead of steel wherever

possible.

9

Carbon fiber reinforced polymer or carbon fiber reinforced plastic (CFRP or CRP or

often simply carbon fiber), is an extremely strong and light fiber reinforced polymer

which contains carbon fibers. The polymer is most often epoxy, but other polymers,

such as polyester, vinyl ester or nylon, are sometimes used. The composite may contain

other fibers, such as Kevlar, aluminum, or glass fibers, as well as carbon fiber. The

strongest and most expensive of these additives, carbon nano tubes, are contained in

some primarily polymer baseball bats, car parts and even golf clubs where economically

viable.

Although carbon fiber can be relatively expensive, it has many applications in aerospace

and automotive fields, such as Formula One. The compound is also used in sailboats,

modern bicycles, and motorcycles, where its high strength-to-weight ratio and very good

rigidity is of importance. Improved manufacturing techniques are reducing the costs and

time to manufacture, making it increasingly common in small consumer goods as well,

such as the tripods, fishing rods, hockey sticks, paintball equipment, archery equipment,

tent poles, racquet frames, stringed instrument bodies, drum shells, golf clubs, helmets

used as a paragliding accessory and pool/billiards/snooker cues.

The material is also referred to as graphite-reinforced polymer or graphite fiber

reinforced polymer (GFRP is less common, as it clashes with glass fiber reinforced

polymer). In product advertisements, it is sometimes referred to simply as graphite fiber

for short.

2.3.1.1 Manufacturing Process of Automotive Hood using Vacuum Bagging

Before the material in any resin mixture, make sure have cut the required amount of

glass fabric (enough to cover the overlapping part with about 1.5 inches), providing an

area to put the vacuum bag where it can sit for a few hours and you've boiled the kettle

(if you want to use a hot water bottle to cure faster). Prepared bristle brush and a cup of

acetone to clean the mixing cup and brush immediately after use it. Vacuum bags needed